1-800-315-5533 • service@easykleen.com • www.easykleen.com

Owner's ManualCommercial and Industrial

Cold Water Gas

Cold Water Gas • Rev. 12/05/2017

Easy-Kleen Pressure Systems

1-800-315-5533

This manual contains operational information that is specific for

commercial and industrial cold water, gas driven machines.

Read the following instructions carefully before attempting to assemble,

install, operate or service this pressure washer. Failure to comply with these

instructions could result in personal injury and/or property damage.

Table of Contents

IMPORTANT SAFETY INFORMATION .................................................................................................. 3

SPECIFICATIONS ....................................................................................................................................... 5

INTRODUCTION ........................................................................................................................................ 6

OPERATING INSTRUCTIONS .................................................................................................................. 7

CHEMICAL APPLICATION..................................................................................................................... 9

WINTER PUMP PROTECTION ............................................................................................................... 9

GENERAL MAINTENANCE .................................................................................................................... 10

MAINTENANCE CHECKLIST ................................................................................................................ 10

GLOSSARY OF TERMS ........................................................................................................................... 12

COMPONENT IDENTIFICATION ........................................................................................................... 13

QUICK DIAGNOSTICS AND SOLUTIONS GUIDE .............................................................................. 17

MANUFACTURER’S WARRANTY ........................................................................................................ 18

SERVICE MANUAL ................................................................................................................................. 11

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Cold Water Gas • Rev. 12/05/ 2017

IMPORTANT SAFETY INFORMATION

Easy Kleen's first priority is the safe operation of our high pressure cleaning equipment. This

can be achieved by following the operation and maintenance instructions as explained in this

manual and all other enclosed information.

This manual contains essential information regarding the safety hazards, operation, and

maintenance associated with this machine. The manual should always remain with the machine,

including if it is resold.

ALL CAUTIONS AND SAFETY WARNINGS MUST BE FOLLOWED TO AVOID

INJURY OR DAMAGE TO EQUIPMENT.

THIS EQUIPMENT IS TO BE USED ONLY BY TRAINED OPERATORS AND MUST

ALWAYS BE ATTENDED DURING OPERATION.

If you need further explanation of any of the information in this manual, suspend any activity involving the equipment and call our toll free number for assistance, 1-800-315-5533.

Cold Water Gas • Rev. 12/05/2017

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Cold Water Gas • Rev. 12/05/2017

SPECIFICATIONS

Commercial Cold Water Gasoline

MODEL GPM PSI HP/ENGINE DRIVE

AS327GL 3 2700 6.5 LIFAN DIRECT

AS327GK 3 2700 6.5 KOHLER DIRECT

AS327GH 3 2700 6.5 HONDA DIRECT

AS440GL 3.5 4000 15 LIFAN DIRECT

AS440GK 3.5 4000 14 KOHLER DIRECT

AS440GH 3.5 4000 13 HONDA DIRECT

AS440GHGP 4 4000 13 HONDA DIRECT

AS440GKGP 4 4000 14 KOHLER DIRECT

Industrial Cold Water Gasoline

MODEL GPM PSI DRIVE HP ENGINE

IS3504G-K 4 3500 GEAR BOX 14 KOHLER IS3504G-H 4 3000 GEAR BOX 13 HONDA

IS3506G 6 3500 GEAR BOX 24 KOHLER IS3607G 7 3600 BELT 25 KOHLER IS3508G 8 3500 BELT 25 KOHLER

IS3675G-JB 7.5 3600 GEAR BOX JABSCO PUMP 25 KOHLER

IS2512G 12 2500 BELT 38 KOHLER

IS3010G 10 3000 BELT 38 KOHLER IS5005G 5 5000 BELT 25 KOHLER IS6045G 4.5 6000 BELT 25 KOHLER

IS7040G 4 7000 BELT 25 KOHLER

Industrial Cold Water Diesel

MODEL GPM PSI DRIVE HP ENGINE

IS3204D 4 3200 BELT 9.8 KOHLER IS5005D 5 5000 BELT 26 KOHLER

IS7004D 4 7000 BELT 26 KOHLER IS8008D 8 8000 GEARBOX 58 KUBOTA

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Cold Water Gas • Rev. 12/05/2017

INTRODUCTION

Thank you for selecting a quality Easy-Kleen product. We are pleased to have you included

among the many satisfied owners of Easy-Kleen cleaning machines. Years of engineering

have gone into the development of these fine products and only top quality components and

materials are used throughout. Each machine is carefully tested and inspected before leaving our

plant to ensure years of dependable performance.

To continue to receive satisfactory performance, remembering that this machine represents a

substantial investment on your part, and if properly cared for and maintained it will return this

investment many times over. As with all mechanical equipment, your machine requires proper

operation and maintenance as outlined in this manual for maximum trouble free life.

This manual has been prepared under the direction of our engineering and service technicians.

Their experience in designing, manufacturing, installing and servicing our equipment from our

company’s inception is condensed in this manual. They know what information the end user

needs in order to get the optimum performance from their pressure washer. Please read

carefully.

This manual contains information that will be specific for your pressure washer, as well as

similar models.

Carefully review any additional manuals that have been included with your system and

follow ALL ADDITIONAL OPERATING INSTRUCTIONS AND SAFETY NOTICES.

They are specific for the quality components that have been used to manufacture your

machine and are an integral part of the operating and maintenance procedures.

Easy-Kleen is proud of the equipment that we design and manufacture and we thank you for

making us your # 1 choice in pressure washers. If you have any questions please do not hesitate

to call us at 1-800-315-5533.

Our goal is that you will be satisfied with the performance, quality, and service you receive

from Easy Kleen, now and in the future.

PLEASE READ MANUALS CAREFULLY BEFORE USING MACHINE. EXAMINE

MACHINE AND CRATE CAREFULLY FOR SHIPPING DAMAGE OR MISSING

PARTS. REPORT PROMPTLY ANY SHORTAGES OR DAMAGE CLAIMS TO

FREIGHT CARRIER OR DEALER.

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Cold Water Gas • Rev. 12/05/2017

OPERATING INSTRUCTIONS

1. Perform pre-start maintenance inspection on all applicable systems prior to operating the

machine. This is essential for safe, effective and efficient operation. You will get optimum

performance from your system ONLY if these instructions and inspections are followed. Any

indication that the pressure washing system was not operated and maintained according to these

instructions may result in voiding the manufacturers’ warranty.

Location – These machines are gasoline powered and must be used outside in a well ventilated

area.

Controls – Make sure all controls are turned to the off position.

Pump – Oil Level - Ensure that the pressure washer is on a level surface. Check oil level on dip stick. If the level is low, add the correct oil to the proper level. USE ONLY SAE 30 W NON-

DETERGENT OIL OR HYDRAULIC 68. DO NOT OVER FILL.

Gas Engine - Gasoline Level – The engine is a 4 cycle and uses regular octane, unleaded fuel.

DO NOT USE MIXED FUEL. Refer to the engine operation manual included with your

pressure-washing unit.

Gas engine - oil level – The engine is a 4 cycle and uses 10W30 detergent oil. Refer to Glossary

or engine manual.

Diesel engine – Refer to engine operation manual included with your high pressure cleaning equipment for oil and fuel recommendations.

Visually inspect all electrical components to assure they are in good condition, showing No

signs of exposure, breakage or splicing.

Visually inspect all hoses, nozzles and guns to assure they are in good condition. If

replacements are necessary they must be rated to withstand the machine’s operating

pressure.

2. Attach high-pressure hose to water outlet quick coupler Attach the other end of high pressure

hose (with quick coupler) to gun and wand assembly. Ensure that coupler connections are tightly

locked together. Apply a sharp pull on hose to confirm they are secured.

Attach wand nozzle specific to task requirements (i.e. chemical or high pressure).

[Quick Coupling Operation – Pull back sleeve end and insert male end into nozzle quick coupler,

release sleeve and confirm connection by pulling on nozzle].

3. Attach water source to water inlet located on pump. The water source must be attached with agood quality standard garden type hose (1/2” minimum is required). Connect male fitting into

water inlet on pump. Make sure that the inlet screen/filter is intact and fitted correctly. Turn on

water source. WATER MUST BE IN SUFFICIENT SUPPLY, AND PRESSURE MUST BE

BETWEEN 20 –60 PSI TO ENSURE PROPER AND SAFE OPERATION. Specific attention should be given if using a well water supply. Ensure water is flowing from end nozzle with trigger gun pulled. Deplete system of all air.

**Quick Coupler Operation – Pull back sleeve end and insert male end into nozzle quick coupler, release sleeve and confirm connection by pulling on nozzle.

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Cold Water Gas • Rev. 12/05/2017

4. Start gas/diesel engine

Refer to instructions in engine manual. You may need to hold wand trigger open while starting

engine in order to let it turn over more easily. MAKE SURE THAT THE ENGINEEXHAUST IS NOT FACING ANY FLAMMABLE MATERIALS.

4. Pressure adjustment - The pressure regulator (unloader) is located on the pump (see diagram).

It controls the pressure being generated by the pressure washer. This regulator may be adjusted to

desired pressure by turning the adjustment knob. Turning the adjustment knob clockwise will

increase pressure. NEVER OPERATE SYSTEM AT A HIGHER PSI THAN THE

MAXIMUM RATING. This machine has been adjusted to operate at a specific maximum

pressure as per the machine specifications. Pressure may be reduced for lighter use by turning the

unloader counter clockwise. If continuing to turn the unloader clockwise does not increase the

pressure, then this implies the maximum has been reached for the system. Any further turning of

the unloader will cause the pressure to spike when the wand trigger is released, resulting in

possible damage to the machine. To avoid this effect, loosen the unloader (counter-clockwise)

until the pressure just starts to drop (see pump head pressure gauge) and until it no longer exceeds

the maximum pressure rating for the machine.

5. You are now ready to start the cleaning operation - Pull trigger on the gun and wand

assembly to start cleaning. To stop pressurized water, release trigger. DO NOT LEAVE UNIT

RUNNING WHEN NOT IN USE. If left running, water will continuously be forced through the

bypass hose and back into the pump, which will cause the pump to overheat.

6. To stop operation. Turn off engine. Squeeze and release wand trigger after shutting off to

relieve system of pressure.

7. Prior to storage – Inspect pressure washer for any damage or required maintenance. If your

machine is to be exposed to cold weather, please refer to winter pump instructions found in this

manual. If possible, do not allow unit to remain outside in the elements.

**Warning – If unit is left running while not in use, pump damage may occur. Do not leave unit running while not in use!

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Cold Water Gas • Rev. 12/05/2017

CHEMICAL APPLICATION

Downstream Chemical Injection: Standard on direct drive units, optional on others. High

Pressure Soap is an optional feature.

NOTE: Do not remove back flow preventer as chemical may flow back into potable water

source. For standard chemical injection, ensure the black nozzle is properly fitted at the

end of the wand. The chemical injector will not function if this nozzle is not fitted.

1. Chemical preparation – Select detergent/chemical that best suits your cleaning task. Prepare

dilution according to the manufacturer’s instructions. The volume of chemical being used may be

adjusted at valve located on the chemical injector. Note: for EK Pumps, the volume is preset and

cannot be adjusted.

2. Insert the intake hose, located on the chemical injector at the pump, into the chemical being

used.

3. Fit black nozzle on the standard wand, or for the dual wand, turn adjustment knob on, and

adjust for required flow rate. For high pressure soap systems, the black nozzle is not needed; use

one of the other wand nozzles.

4. To apply chemical, engage trigger on pressure wand assembly. Turn chemical injector’s nipple

to adjust flow. For the high pressure soap systems, open ball valve and engage trigger.

5. Chemical can now be applied through pressure wand assembly. It will take 5 – 15 seconds for

chemical to travel to spray nozzle. The volume of chemical being used may be adjusted at the

chemical injector.

6. For best results apply chemical from bottom to top, and allow for proper penetration time prior

to rinsing. Do not allow chemical to dry. Rinse from bottom to top and then top to bottom.

WINTER PUMP PROTECTION

The following procedure MUST be used when the pressure washing unit is stored at

temperatures below freezing.

1. All water must be drained or blown (via compressed air) from system. Connect a short piece

of male fitted ½” garden type hose on to the water inlet on the pump assembly.

2. Place the open end of the hose into a wide mouthed container of full strength, winter rated,

vehicle windshield washing fluid or Anti-Freeze, RATED FOR MINIMUM -40°C.

3. Connect the pressure wand assembly.

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Cold Water Gas • Rev. 12/05/2017

4. Start the pump and engage trigger on the pressure gun. Operate the system until the fluid runs

the same color as the windshield washing fluid. Your machine is now prepared for storage.

5. Disconnect fluid supply, blow out with compressed air, and cap end.

GENERAL MAINTENANCE

Water Condition Use a softener on your water system if local water is known to be high in mineral content. The

advantages of soft water are very beneficial: prevents scale buildup in heater coil, cleans better

with considerably less detergent, and prevents streaking on painted surfaces and glass when

rinsing.

MAINTENANCE CHECKLIST

Maintenance for Pump

Daily: 1. Check oil for proper level and adjust accordingly.

2. Examine the quality of the oil.

3. Check pump for oil and/or water leaks.

4. Inspect and clean inlet filters.

Weekly:

1. Examine all fittings, components, hoses, connections, and nozzles for damages, loose

parts, or leaks. – Replace accordingly—

Recommendation for Oil Changes and Component Replacement:

1. Change the oil in the pump after the first 50 hours and every 500 hours after the initial

oil change. Use SAE 30 W Non-Detergent for GP Pumps and Hydraulic 68 for EK

Pumps.

2. Change all other components on the pump as needed.

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Maintenance for Gasoline Engine

Daily: 1. Check oil for proper level and adjust accordingly.

2. Examine the quality of the oil

3. Examine the air cleaner element

Weekly:

1. Examine engine components for damages, loose parts, or leaks.

Recommended Schedule for Oil Changes and Component Replacements:

1. Change engine oil after first 5 hours and every 100 hours after the initial oil change.

Use 10w-30 engine oil.

2. Replace Spark Plug every 100 hours.

3. Change air cleaner element every 100 hours.

4. Check fuel filters every 300 hours.

5. Change all other components on engine as needed.

This manual is intended for technical personnel to assist in the diagnosis and repair of issues with pressure washers. This manual is not intended for use by non-technical personnel. It is advised to always refer to competent technical personnel when repairs are advised to avoid equipment damage or potential personnel injury. If you have any technical questions please do not hesitate to call us at 1- 800-315-5533.

Easy-Kleen Pressure Washers Service Manual

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Cold Water Gas • Rev. 12/05/2017

GLOSSARY OF TERMS

PSI – Pounds per square inch. Pressure washers are designed and rated to operate at a specific

PSI. Operating at pressures exceeding the maximum rating could result in damage to the unit

and/or SEVERE PERSONAL INJURY.

GPM – Gallons per minute. The orifice on the pressure wand assembly has been selected to

deliver up to the maximum GPM for your machine.

PRESSURE WAND ASSEMBLY – This refers to the gun, wand, and nozzle.

PUMP – The pump moves the water through the system and delivers it to the pressure wand

assembly.

UNLOADER VALVE – Is a valve located at the head of the pump for unloading water back

into the bypass when the trigger gun is shut off. It also reduces the load on pump when gun is

off.

OIL, PUMP – The oil used within the pump to lubricate its operation. It is important to use only

SAE 30 W Non Detergent (for GP Pumps) or Hydraulic 68 (for EK Pumps) in the pump.

OIL, GASOLINE ENGINE – Gasoline Engines need appropriate lubricant. Use 10W30

detergent oil.

BACK FLOW PREVENTER – Device to prevent flow backwards into potable water supply.

MAXIMUM WORKING PRESSURE - Each machine is equipped with a safety pressure relief

valve which prevents over pressurization of the high pressure system. It is an important safety

device and must not be tampered with in any way.

PRESSURE SWITCH - A pressure switch is used to control the motor for the auto stop/start

feature (see diagram).

FLOW SWITCH – A flow switch is installed on the outlet of the water pump in auto stop/start

models and will shut off the pump and motor in the absence of water flow as well as turning it

back on when flow is detected (by squeezing the trigger).

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Cold Water Gas • Rev. 12/05/2017

COMPONENT IDENTIFICATION

Commercial Model:

Water Pump

Engine

Wand and Nozzles

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Cold Water Gas • Rev. 12/05/2017

Industrial Model:

Pressure Wand Assembly:

Nozzle Quick Coupler Spray Gun

High Pressure Hose

Trigger

Wand Nozzles

Black Nozzle for Downstream Chemical Application

10 Gallon Poly Fuel Tank for Engine

Engine

Water Pump

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Cold Water Gas • Rev.12/05/2017

Commercial Model Pump Assembly:

Water Inlet

Water Outlet Quick Connector

Water Pump

Chemical Injector (Downstream)

Unloader

Oil Dipstick

Thermal Relief Valve

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Cold Water Gas • Rev. 12/05/2017

Industrial Model Pump Assembly:

Water Inlet

Water Filter

Pump Head Pressure Gauge

Unloader

Water Pump

Water Outlet Quick Connector

Thermal Relief Valve

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Cold Water Gas • Rev. 12/05/2017

QUICK DIAGNOSTICS AND SOLUTIONS GUIDE

PUMP TYPE OF OIL

EK Pump Hydraulic 68 (650ml)

GP Pump 30W SAE Non-Detergent

PROBLEM POSSIBLE CAUSES SOLUTIONS

PRESSURE

No pressure

or

Very low pressure

Metal in oil - Examine oil in pump to see if there is metal in oil.

- If you find traces or pieces of metal, your pump

has damaged components.

Dirt in water

- Verify if there is dirt in nozzle tip or in valves in pump.

- If nozzle is plugged, clean or replace it.

- If valves in pump are clogged, clean valves.

- If valves in pump are damaged, replace valves.

Wrong nozzle size

- Make sure you have the right nozzle size. The black

nozzle will drop pressure in order to use chemical injector

and is only for soap or chemical. If you are not using soap,

use a different color.

Pressure too high

Wrong nozzle size

- Make sure you have the right nozzle size.

Unloader adjusted improperly

or damaged

- Check pressure of pump with a pressure gauge and adjust

to desired pressure.

- If you cannot reduce pressure, replace unloader.

MANUFACTURER’S WARRANTY

AUG 1ST,

2019

Thank you for your purchase of an Easy-Kleen pressure cleaning system. All original equipment are warrantied for a specific period and on the conditions set forth, that the product is free from defect in materials and workmanship as follows:

Electric Motors

1Phase 18 Months

3 Phase 24 Months

For warranty for these items manufacturer needs to be contacted

Oil Burners Igniters, Fuel Solenoid, Burner Motor, Fuel Assembly, Drive Shaft, Electrodes Blower, Wheel Fuel Pump 1Year Parts

Propane / Natural Gas Burners

Burner Rings, Gas Valves, Gas Valve Control Board

1Year

Fitting All Fittings, Brass Stainless Steel, Steel, Etc. 30 Days

Heating Coils

All Coils 1Year Replacement

Under 5100 PSI- 5 Year Prorated 25% Year each year for 4 Years

Gas Motors Honda and Kohler have manufacturer’s warranty. Manufacturer does not cover fuel systems.

Lifan Motor

Contact Easy-Kleen for Warranty

1Year (for commercial use)

Frames

Limited warranty on Frames, Belt Guard, Welds due to manufacture defect.

Paint is not covered under the manufacturer’s warranty due to the aggressive environment or natural wear.

Plastic Tanks Water or Fuel 1Year

Accessories/ Wear Items

Unloader, Regulating Valves, Safety Valves, Jetter Valves, Check Valves, Foot Valves, Pulsation Dampeners, Trigger Guns, Rotary Nozzles, Chemical Injectors, Hose, Hose Reels, Sandblast Kits, Surface Cleaner, Water Broom, Water Strainer, Belts, Ball Valves, Swivels,

Balanced Relief Valves, Accumulator Lances

90 Days

Electrical Components

Switches, Time Over Loads, Contactors, Transformer, Thermostat, Vacuum Switches, Flow and Pressure Switches, Relays, Primary Controls

90 Days

No Warranty Items Fuel Filters, Nozzles, O- Rings, Thermo Relief Valves (Pump Seals, Valves, Plungers)

ANY PARTS NOT LISTED ABOVE CALL FOR WARRANTY TIME FRAMES

NOTE* Due to original equipment manufacturer’s requirements, Easy-Kleen is not permitted to perform warranty repairs or claims for electrical motors, gas, or diesel engines. Please contact Easy-Kleen service department for a local warranty representative.

LIMITATIONS OF LIABILITY Easy-Kleen liability for special, incidental, or consequential damages is expressly disclaimed. In no event shall Easy-Kleen’s liability exceed the purchase price of the product in question. Easy-Kleen makes every effort to ensure that all illustrations and specifications are correct, however, these do not imply a warranty that the product is merchantable or fit for a particular purpose, or that the product will actually conform to the illustrations or specifications. Our obligation under this warranty is expressly limited at our option to the replacement or repair at our manufacturer location, is such part or parts at inspection shall disclose to have been defective. Easy-Kleen does not authorize any other party, to make any representation or promise on behalf of Easy-Kleen or to modify the terms, conditions, or limitations in any way. It is the buyer’s responsibility to ensure that the installation and use of Easy-Kleen products conform to local codes. While Easy-Kleen attempts to ensure that its products meet national codes, it cannot be responsible for how the customer chooses to use or install the product. THE WARRANTY CONTAINED HEREIN IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING ANY IMPLIED WARRANTY OF MERCANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY LIMITED TO THE DURATION OF THIS WRITTEN WARRANTY.

Easy-Kleen reserves the right to make any changes to an Easy-Kleen product at any time without incurring any obligation with respect to any product previously, ordered, sold, or shipped.

PUMP WARRANTY TIME LINE

Cat Pumps

Direct Drive Pumps 2 Years

Car Wash Pumps (Including all models used in Car Wash or Portable Fresh Water Pressure Cleaning applications

5 Years

All other pumps not listed above 1 Year

Giant Pumps

Pressure Washer and Self- Serve Car Wash Applications 5 Years

All other Giant Pumps, Industrial and Consumer Pumps 1 Year

Lifetime on Manifolds due to Manufacture defects

AR Pumps

Plunger Pumps 5 Years

Axial Pumps 1 Year

AR Accessories 90 Days

General Pumps

Manifolds 5 Years

Pressure Washer Pumps 5 Years

EK Pumps

Manifolds 5 Years

Pumps 1 Year

Accessories 90 Days

Manufacturer does not cover wet end of Pump Seals, Valves, and Plungers.

WARRANTY REPAIRS Warranty claims must first contact Easy-Kleen’s Service Department to be issued a preauthorized repair number (PARN). You will need a copy of your invoice and the equipment serial number.

If new parts are needed, they will be invoiced to you as normal. Defective parts are to be sent to us PREPAID for warranty consideration. If a part is found to be defective, a credit will be issued to cover the costs of parts. All work is be performed at the manufacturers’ place of business when returned PREPAID. This warranty will not cover labor if warranty work is conducted at the customer’s place of business. Road service will be charged at the normal rate in these situations.

WARRANTY DOES NOT COVER: • When warranty part is warrantied the warranty time frame does not re-start. • Warranty freight cost will be covered by Easy-Kleen for the first 30 days of sale of the machine due

to manufacture defect or workmanship. • Neglect of the periodic maintenance as specified in the owner’s manual. • Improper repair or maintenance. • Operating methods other than those indicated in the owner‘s manual. • The use of non-genuine Easy-Kleen parts or accessories other than those approved by Easy-Kleen • Exposure of chemical agents, such as: Sea Water, Sea Breeze, Salt, or other environmental phenomenon. • Collision, fuel contamination or deterioration, neglect, unauthorized alteration or misuse. • Warranty does not cover travel or time if a service call is needed. • Warranty does not apply when pump or accessory is altered or used in excess of recommended

speeds, pressure, temperatures, or handling fluids not suitable for pump or accessory material. • Construction warranty does not apply to normal wear. • Warranty does not apply to normal wear (such as but limited to seals, packing valves, plungers and

sealing O-Rings), freight damage, freezing damage or damage caused by parts or accessories not supplied by Easy-Kleen.

• After 30 days freight will become chargeable. • Warranty covers In-House Labour and Parts if manufacture defect is repaired at an Easy-Kleen approved Service Center.

WARRANTY DOES NOT COVER DEFECTS CAUSED BY: • Improper or negligent operation or installation, accident, abuse, misuse, neglect, unauthorized modifications, including, but not

limited to, the failure of the customer to comply with recommended product maintenance schedules. • Improper repairs • Neglected maintenance/incorrect operation (specified in the Owner/Operator’s Manual • Unapproved devices or attachments • Water sediments, rust corrosion, thermal expansion, scale deposits or a contaminated water supply or use of chemicals not approved

or recommended by Easy-Kleen Pressure Systems Ltd. • Improper voltage, sudden voltage spikes or power transients in the electrical supply • Usage which is contrary to the intended purpose of the equipment • Natural calamities or disasters including, but not limited to, floods, fires, wind, freezing*, earthquakes, tornados, hurricanes and

lightning strikes

*Includes damage done to components that come in contact with water as a result of freezing in a non-winterized machine.

service@easykleen.com 1-800-315-5533 www.easykleen.com

POWER SYSTEM DIAGNOSTICS - Gas Motor Not Starting PROBLEM POSSIBLE CAUSE SOLUTION

Gas motor not starting

Fuel Check to see if proper fuel levels are maintained

No ignition Check ignition by removing spark plug from cylinder. If electric start, try starting using the recoil starter.

Electric Starter/Battery Recharge or replace battery.

Fuse blown in key switch 18 amp engine, open key switch, replace 30 amp fuse

Spark Plug - strong gas

smell

Flooded Wait 5 minutes before attempting to restart.

No ignition Check ignition by removing spark plug from cylinder. If electric start, try starting using the recoil starter.

Bad plug Check spark plug and replace if necessary. Carbon deposits can indicate a fouled plug or too much

fuel.

Plug does not fire Poor connection Inspect the ignition connection.

Bad magneto Check the source of spark plug for engine ignition.

Bad ignition system Poor connection Check the source of spark for the engine ignition.

Spark Plug - no gas smell

No fuel to cylinder Check fuel delivery from carburetor to cylinder. Check carburetor float bowl for fuel.

Fuel line restricted Inspect fuel line to carburetor for restrictions or clogging. Flexible line may be kinked.

Stuck carburetor float Unstick float

Clogged carburetor needle valve Unclog needle valve.

Bad fuel pump Replace fuel pump.

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FLUID SYSTEM DIAGNOSTICS - Flow and Pressure PROBLEM POSSIBLE CAUSE SOLUTION

No Flow

No power Make sure pump is operating. Check drive belts and couplings, make necessary adjustments.

Trigger gun valve Check trigger gun, repair or replace.

No water source Ensure water supply is not restricted and hoses are in good repair and not kinked.

Clogged spray nozzle Check spray nozzle, repair or replace.

Clogged inlet filter Check inlet filter, repair or replace.

Float Valve stuck (optional) Float valves can become stuck in the "UP" position. Manually dislodge and inspect for problems.

Faulty unloader valve Remove and check for proper action, repair or replace.

Low pressure, adequate

flow

Incorrect or no spray nozzle Nozzle should be properly sized for the system. Low pressure indicates that the nozzle in use is

too large.

Worn spray nozzle Replace nozzle when it shows signs of internal erosion.

Debris in valves Clean valves and check O-rings for pits and cracks.

Lance on low pressure Adjust pressure so the water flows through properly.

Unloader is not adjusted correctly Adjust unloader to proper level.

Pressure gauge inaccurate Use a new pressure gauge on a quick connect at outlet to check system pressure and replace if

gauge is faulty.

Pump packings bad If low pressure persists, pump packings may need replaced.

Low pressure, low flow

Volume Improperly adjusted If unit has volume adjustment, it may need readjustment

Discharge leaks Look for leaks on the discharge side of system.

Downstream chemical injector

(Dema) Remove the injector and retest system. If the flow is restored, replace the injector.

Loose drive belts If belts do not have proper deflection, replace them.

Pump not running at rated speed Check engine throttle and see that the motor is rated for the same speed as the pump.

Stripped pump drive coupling Inspect coupling and repair or replace.

Defective easy start valve

(optional) Check the start or throttle-back valve for proper operation.

Malfunctioning motor or gear Ensure that the motor or engine is working properly

Unloader stuck in bypass Piston assembly may be stuck or fouled

Low pressure, low flow -

Bogs

Outlet restriction Build up can restrict flow. If water is not flowing freely, flush with garden hose to isolate the clog

or restriction.

Clogged nozzle Distorted spray pattern can indicate a clogged nozzle.

Nozzle too small Ensure nozzle is proper size for the system.

Hose restriction Correct any kinks or restrictions. Replace crushed hoses.

Debris in the system Debris can lodge in the discharge side of the system (valves, fittings, injectors, filters) Flushing

with water may correct it.

PROBLEM POSSIBLE CAUSE SOLUTION

Excessive pressure

Small spray nozzle Nozzle must be properly sized for the rated flow and pressure. Reset unloader or pressure relief

if nozzle size is changed.

Faulty pressure gauge Check the pressure gauge using a properly calibrated pressure gauge on quick connects at the

equipment outlet.

Improperly adjusted unloader Adjust to the proper pressure using pressure gauge.

Faulty unloader Check the unloader action. If it is not working properly, it may need repaired or replaced.

Pump chatters, cavitation,

vibration

Air in system Inspect places where air can enter the system. i.e. fittings, hose, connections etc.

Chemical line not submerged If the chemical valve is on, ensure that the chemical line is fully submerged in the chemical

Inlet line restricted All inlet connections should be snug and not kinked to reduce the chances of pump starvation.

Inadequate water supply Water supply to the system must meet or exceed the rated flow (GPM) on the serial number

plate. Faucet must be completely opened or water above the tank outlet in a gravity fed system.

Float valve stuck (optional) If float valve is stuck in the up position, water can not enter the float tank. Unstick valve if

possible of replace if necessary.

Turbulence in float tank (optional) Excessive turbulence allows the pump to draw air into the system. Correct excessive turbulence.

Inlet or inlet strainer clogged Regularly clean the inlet and inlet strainer to keep debris from entering the float tank

Water supply too hot Inlet temperature should not exceed 140F - 160F range.

Inlet line vibrates

Air in system Inspect places where air can enter the system, i.e., fittings, hose, connections etc.

Debris in inlet check valves If there is no float tank and the outlet line does not vibrate, the inlet check valve may be

clogged. Remove debris. Check O-rings under valves.

Outlet line vibrates

Air in system Inspect places where air can enter the system, i.e., fittings, hose, connections etc.

Debris in inlet check valves If there is no float tank and the outlet line does not vibrate, the inlet check valve may be

clogged. Remove debris.

Pump packing bad If they show signs of ware or damage, replace them.

Inlet and outlet lines vibrate Inlet and outlet check valves

fouled Look for the source of debris in the inlet and discharge check valves and remove.

FLUID SYSTEM DIAGNOSTICS - Unloader PROBLEM POSSIBLE CAUSE SOLUTION

Very low or no flow Unloader stuck in bypass Isolate the flow problem. If it occurs before the unloader discharge point, check the piston

assembly to see if it is fouled or stuck in bypass mode.

Unloader will not unload Debris in unloader Take bottom nut off unloader, identify ball, spring and seat. Clean out any debris and

Sever leak on the outlet of unit Check for leaks and repair.

Unloader (flow) cycles with

system under pressure

Improper flow Any variation in flow form what the orifice is sized can cause cycling. System must produce the

rated flow constantly.

Nozzle to small A nozzle that is too small can cause the flow to be reduced.

Nozzle clogged A distorted spray pattern indicates a clogged nozzle.

Improper unloader orifice The systems rated output should indicate the proper sized orifice for your system.

Unloader orifice clogged Check the orifice for clogs and clear out any debris.

Injector orifice clogged If the system has a Venturi injector downstream of the unloader, check the orifice for clogs.

Other downstream restriction Scale buildup can restrict flow. Check: controls, valves, switches, trigger gun, and lance.

De-scale as necessary and begin preventive maintenance program for scale prevention.

Pump not delivering the rated

pressure See low pressure or low flow diagnostics.

High water supply pressure Check inlet water supply for excessive pressure.

Unloader (flow) cycles with

system in bypass

No restrictions on the unloader Check unloader bypass port to see if a flow restrictor is properly installed. Install one if none is

present.

Downstream leakage (excessive) Causes the unloader to since a continuing flow and divert it to the closed gun. Repair or replace.

Accumulator downstream (option) Remove the accumulator from the system.

Unloader (pressure)

produces smooth flow & low

volume

Unloader adjusted too low Adjust the unloader using the pressure gauge for the correct pressure.

Spray nozzle clogged A distorted spray pattern indicates a clogged nozzle.

Spray nozzle too small A small nozzle causes a reduced flow and cycling may result.

Injector orifice blocked If the system has a Venturi injector downstream of the unloader, check the orifice for clogs.

System not delivering rated flow See flow diagnostics.

Unloader (flow) produces

smooth flow & low volume

Unloader adjusted too low Adjust unloader and regulator until proper pressure is achieved.

Unloader valve stuck in bypass If unloader is sticking, repair or replace as necessary.

Restriction in system

Downstream restrictions can cause a reduction in flow. Check; controls, valves, switches, trigger

gun, and lance. Descale as necessary and begin preventive maintenance program for scale

prevention.

Unloader (pressure)

produces low flow and

normal pressure

Unloader adjusted too low If the unloader is diverting flow to bypass it may be adjusted too low, readjust as necessary.

Spray nozzle too large Ensure the proper nozzle is installed on system.

Internal nozzle erosion The number of hours of usage can give you an idea to the extent of the ware. If in doubt, change

Insufficient pump pressure Check pump seals and packings and tighten drive belts.

Unloader (flow) produces

low flow & normal pressure

Unloader adjusted too low If unloader is diverting flow to bypass, readjust using the pressure gauge.

Nozzle too large Ensure the proper sized nozzle is being used.

Unloader (pressure) leaks

from main spring or

adjusting bolt

Shaft O-ring in valve body warn Check O-rings for ware or damage and replace as necessary.

Unloader (flow) pressure

increases when trigger

released

Unloader piston stuck or frozen Check unloader shaft for proper action. Release piston and shaft or replace unloader.

Bypass port clogged or restricted Ensure that unloader bypass port is not clogged

Excessive tension on main spring If tension is incorrect, adjust or replace as necessary.

Unloader (flow) leaks water

around adjusting bolt Sleeve O-ring worn Check O-rings for ware or damage and replace as necessary.

FLUID SYSTEM DIAGNOSTICS - Leaking

ANY LEAKS SHOULD BE REPAIRED ASAP TO PREVENT DAMAGE TO THE SYSTEM.

PROBLEM POSSIBLE CAUSE SOLUTION

From inlet Garden hose washer Ensure the washer is present and in good condition.

From low pressure (inlet)

line fittings Loose clamps or connections Low pressure line should be properly sealed on barb and tightly clamped.

From float tank(option) Float tank full of water or stuck If float is not floating above water, check the float to see if it has filled up with water. If

necessary, drain and seal.

From pressure fittings Fittings not tightened or taped, or

cracked Usually metal to metal fittings should be taped with Teflon tape or lock tight to provide a tight seal.

From quick connects Bad O-rings If quick connect O-ring shows wear or damage, replace it.

From pump Bad packing If the seal leak is detected under the pump manifold, packing may be worn and in need of

replacement.

From trigger gun

Bad rod O-ring If O-rings show wear or damage, they may need replaced.

Stripped connectors Physical damage may not be apparent, but unseen warping from freezing or extreme pressure

can still cause leakage.

From nozzle

Weep gun (optional) If a weep gun has been installed, check the gun valve seat to ensure it is functioning properly.

Damage gun valve ball or seat Inspect trigger gun valve assembly for damage or ware to ball or seat. Lodged debris can stop

valve from closing. Repair with kit or replace.

From unloader Bad O-rings or seals If quick connect o-ring shows wear, damage or improper seating.

From variable pressure

Lance(option) Bad O-rings at adjusting knob Inspect O-rings for ware or damage and replace as necessary.

Unloader will not unload Debris in unloader

Take bottom nut off unloader, identify ball, spring and seat. Clean out any debris and

reassemble.

Sever leak on the outlet of unit Check for leaks and repair.

From pressure relief valve

System over pressure See pressure and flow diagnostics to find the cause of the excessive pressure and correct it.

Clogged nozzle Spray pattern will be distorted if nozzle is clogged, clean out.

Trigger gun valve not working If trigger gun valve action is not correct, repair or replace.

Excessive pressure spike If water spurts from valve when trigger is released, check unloader adjustment. Pressure spike

should be below the level where pressure relief valve is activated.

Wear or damage to ball or seal Inspect ball and seal for damage and adjust as necessary.

Improper relief valve adjustment Adjust valve properly.

FLUID SYSTEM DIAGNOSTICS - Trigger Gun/Spray Nozzle PROBLEM POSSIBLE CAUSE SOLUTION

No nozzle flow from nozzle

when trigger depressed.

Broken piston rod in trigger gun If water flows through discharge hose without gun, check trigger gun valve piston rod and

replace if necessary.

Missing metal insert in trigger gun

(European style gun) Inspect to assure insert is in place.

Blockage in system past gun Check nozzle or spray accessory for blockage and clear it.

Excess pressure when

trigger gun is released Excessive pressure spikes

After unloader increases pressure to a maximum, further adjustment will only increase the

pressure spikes. Re-adjust.

Flow not stopping when

trigger gun released

Broken return spring on trigger gun If trigger action is too loose, return spring may need replaced.

Debris in gun valve Debris in gun valve can stop piston return. Clear debris.

Trigger action sticks Keeper plug too tight It may be possible to loosen plug slightly without leakage but it will likely need replaced.

Trigger gun leaks

Worn or bad O-ring Check trigger gun o-rings for ware or damage and replace.

Stripped or loose connections Physical damage may not be apparent but unseen warping from freezing or sever over pressure may still cause leaking.

No chemical

Chemical valve closed Black nozzle

Open chemical valve. If It chatters with no chemical delivery, air is being drawn from the

upstream side of the pump. Check fittings, connections and ensure the inlet line is fully

submerged into the chemical jug.

Chemical dried up in the injector Inspect and clean as necessary.

Chemical foot strainer clogged May be a strainer or check valve. Ensure that the ball is not stuck or clogged.

Chemical line kinked Chemical line kinking or binding prevents chemical delivery.

Chemical line too long An overly long chemical line can prevent the pump from drawing chemical into the system. Try

installing a shorter line.

Chemical too dilute Verify chemical strength.

No adjustment for low pressure Downstream injectors only - Low pressure is required for most injectors to draw chemical. If no

adjuster exists it may need low pressure spray nozzle installed on the lance.

Incorrect injector orifice If not properly sized for the systems rated output, chemical delivery problems will result. Check

serial plate for specs.

Excessive chemical

Valve improperly adjusted, check

knob on injector To properly adjust, a chemical flow meter may be used to precisely measure chemical flow.

Chemical dilution to strong Verify chemical strength.

Spray pattern irregular Clogged nozzle Spray pattern will be distorted if nozzle is clogged.

Volume proper, pressure

low

Nozzle too large Ensure that the nozzle is sized properly sized for the system

Internal nozzle wear A loss of pressure may result form gradual nozzle wear. Replace a nozzle of correct size.

Pressure proper, volume

low Clogged nozzle

Spray pattern will be distorted if nozzle is clogged. Check nozzle for clogging if the unit has a

pressure unloader.

BOILER SYSTEM DIAGNOSTICS - Oil Burner Will Not Fire PROBLEM POSSIBLE CAUSE SOLUTION

Not reaching rated pressure

flow Not activating boiler controls Correct the fluid problem first - See fluid systems diagnostics

Thermostat on low setting Thermostat set too low Set thermostat to an output temperature requiring heating.

No or low fuel in tank Burner no getting adequate fuel Check fuel and bring to proper levels. Inspect fuel tank for water or debris.

Low fuel shut-off control activated. Full featured equipment may have a shut off if fuel is low.

No air movement through

stack

No air being supplied Ensure that the blower is working and that the air band or damper is properly adjusted and in

good repair.

Thermal reset tripped Press the thermal reset button on burner motor. If the reset trips again an additional problem

must be sought.

Burner motor or capacitor is bad If motor does not turn, first check thermostat/press switch, the motor starting capacitor and

finally the burner motor itself.

Fuel in the fuel tank

Contaminated fuel in the tank Ensure that the proper clean fuel is being used. If not, siphon any debris or water from the tank.

Improper fuel in the tank If the improper fuel is found in the tank, drain and rinse the tank, then fill with proper fuel.

Low fuel shut-off sensor stuck or

faulty

Check the sensor. The assembly may need to be removed to un-stick the float or to replace it

completely.

Water in the fuel filter bowl Water in fuel supply Drain water from the tank promptly to prevent rusting. If fuel delivery problems persist, check the

fuel pump for rust.

Debris in the fuel filter bowl

Clogged strainer If the fuel strainer or in-line filter is clogged, clean or replace.

Clogged fuel nozzle Replace if there is any evidence of clogging or debris.

Clogged fuel line Check lines for clogging and clear if necessary.

Water comes out drain at

bottom of tank Water in fuel supply

Check only if no fuel in the filter bowl - Drain the tank and check for rust. If problem persists, fuel

pump should be checked for rust.

Cannot smell or see fuel at

stack

No fuel being supplied Check fuel delivery and correct any problems.

No fuel to bleed valve

Air leak to pump Ensure that air is not entering through the lines or connections.

Broken fuel line Ensure that the fuel line is connected and is not broken/punctured.

Clogged fuel filter Check any clogging that exists in the fuel filter

Clogged fuel inlet line Check any clogging that exists in the fuel inlet line.

Frozen fuel pump If the fuel pump is frozen it will need replaced.

Broken fuel pump coupling Check pump coupling if direct or belt driven. Replace or tighten or replace the drive belts if

needed.

PROBLEM POSSIBLE CAUSE SOLUTION

Steady fuel flow at bleed

valve but none in

combustion chamber

Solenoid valve not energizing

Remove the solenoid cover and place blade of an insulated screwdriver in the coil with the

system operating in hot water mode. A good working solenoid will hold the screwdriver in the

solenoid. If not it may need replaced.

Oil pump may have debris, replace as necessary.

Boiler controls activating Solenoid valve coil not energizing If boiler controls work properly, the pressure or vacuum on the fuel pump may be misadjusted.

Check solenoid coil again.

Solenoid valve energizing

Debris in internal fuel pump valve Check for clogging in the solenoid valve inside fuel pump.

Fuel nozzle clogged Check fuel nozzle for clogging and clear if necessary.

Restriction in fuel outlet line Check fuel line from pump to burner for any restriction.

Fuel pump piston frozen closed Check piston in fuel pump to see if it will travel. Free piston or replace fuel pump.

Air and fuel flow proper

No power reaching transformer Ensure the proper voltage is reaching the ignition transformer with a volt meter.

Ignition transformer bad Using a volt meter, ensure that the transformer is supplying the proper voltage.

Electrode gap improperly set Check the gap and readjust if necessary, taking care that the proper distance is maintained from

the fuel nozzle.

Electrode caps cracked Down fired, multi-pass boiler systems have a cap on the top of each electrode. Examine caps

for cracks or carbon build-up and replace if there problems are evident.

Electrode wires loose or damaged Applies to down fired, multi-pass boiler systems - Check the wire to each electrode to ensure

there is a good connection.

Electrodes arcing to fuel lines Electrodes should not be arcing to fuel lines or nozzle. Check electrode for cracking or carbon

build-up.

Transformer bus bars not lining up Applies to gun type burners - Bus bars on the transformer should line up and connect properly

with the electrode terminals

Burner or electrode

assembly fires when

removed from housing

Improper air delivery Check air delivery to combustion chamber. Down fired; check air damper and air bag. Gun type;

Check air bands.

Ignites with air bands closed

down Excessive electrode gap Ensure electrode gap is properly set.

Ignites with air bands

opened up Choked down Open air bands to proper setting.

BOILER SYSTEM DIAGNOSTICS -Gas Burner Will Not Fire PROBLEM POSSIBLE CAUSE SOLUTION

No arc at the ignition pilot

assembly

Spark gap incorrect Check the spark gap and reset if necessary. Check for air in the propane line.

Ignition module bad Check the ignition module and replace if necessary.

Ignition operating properly Boiler controls malfunctioning Check boiler controls for good operation and correct problems.

Boiler controls operating

properly Gas valve malfunctioning

If pilot and boiler controls operate properly, the problem may exist with the gas valve. Replace if

necessary

BOILER SYSTEM DIAGNOSTICS Abnormal

Flame Characteristics - Gas Fired

PROBLEM POSSIBLE CAUSE SOLUTION

Flame intermittently lifts and

returns to gas port "candles" Gas velocity exceeds flame speed

If gas flow is not properly regulated, the regulator may need to be replaced. Gas line may be too

small.

Flame height changes

suddenly Uneven gas supply pressure

Check orifice for partial blockage. If no blockage found, ensure that the gas supply and regulator

are working properly.

Flame floats around the

combustion chamber Insufficient air

Check stack for fuel restriction and correct. It may require new ventilation if the original system is

inadequate.

Flame has yellow tip Flame speed improper Check for proper gas pressure while burner is operating.

Flame comes out from

under burner housing Insufficient air and ventilation Usually occurs at ignition. Check stack for fuel restriction.

Gas burns inside the burner

tube - roars Burner underrated Inquire about a burner with the proper rated capacity.

Burner pops when gas is

shut off Flame travels back into burner Flame travel when the gas is shut off does not damage the unit.

BOILER SYSTEM DIAGNOSTICS

Water Output Temperature Too Low - Oil or Gas Fired PROBLEM POSSIBLE CAUSE SOLUTION

Burner firing normally but

with outlet temp lower than

rated

Thermostat set too low Set the thermostat to proper output temperature.

Burner firing constantly

Inlet water too cold If inlet water is freezing to the touch, the boiler may not be able to reach desired temperature

increase. Use a water supply with a higher temperature.

Sooting Soot build up on the coil can keep the water from reaching the desired If inlet water is freezing to the

touch, the boiler may not be able to reach the desired temperature increase. Use a water supply

with a higher temperature.temperature. Remove all soot from the coil and check for smoking.Scaling

The outlet fitting to the hose can get scale build-up and reduce heat exchange. Descale and

prevent further build-up.

BOILER SYSTEM DIAGNOSTICS - Boiler Controls PROBLEM POSSIBLE CAUSE SOLUTION

No voltage solenoid Boiler control or electrical problem A multimeter can be used to check continuity through controls and pinpoint the problem areas.

Solenoid coil does not

energize

Bad connection to solenoid coil Electrical connections to solenoid valve coil should be tight and not corroded.

Coil bad Check to see if fuel solenoid will energize when the proper voltage is applied. Solenoid may

need replacing.

Boiler control not activating

properly If coil energizes when proper voltage is applied, check boiler controls.

Solenoid coil energizes Problem occurring elsewhere If solenoid valve coil energizes when the cleaner is operating in hot water the problem is

elsewhere. Check the air/fuel delivery.

BOILER SYSTEM DIAGNOSTICS - Pressure Switch PROBLEM POSSIBLE CAUSE SOLUTION

Switch activates when

pressure is reached but

boiler not firing

Control not flowing through switch A multimeter can indicate if the proper voltage flows through the boiler side of the switch. If not

the switch may not need replaced.

Switch improperly wired Switch may be improperly wired for its function.

Switch bad If wiring is proper and still no current flow when activated, switch may need replacement.

Switch does not activate

Plunger fouled or stuck Check pressure plunger to see if it will travel freely. If not, the passage may need cleared.

Plunger not moving far enough Check to see if the plunger is traveling far enough to depress the microswitch. Adjust if

necessary.

Switch activated manually

Current not flowing through switch If switch activates manually but boiler does not fire, current may not be flowing through. The

switch may need replacing.

Microswitch not properly adjusted Microswitch may need readjustment so plunger can trip in.

Switch bad Replace switch with another one.

Problem elsewhere in the system. If switch works manually and current is flowing properly, the problem is elsewhere. Try other

boiler diagnostics.

BOILER SYSTEM DIAGNOSTICS - Vacuum Switch - Optional PROBLEM POSSIBLE CAUSE SOLUTION

Switch activated manually

Improper diaphragm movement Replace switch if improper diaphragm movement is detected.

Low water flow Correct problems related to inadequate water flow.

Air leak in or punctured diaphragm Replace vacuum switch if diaphragm shows an air leak or hole.

Switch shows continuity

when activated Problem elsewhere in system If vacuum switch works properly, continue with other boiler control diagnostics.

Switch does not shows

continuity when activated Switch contact bad Replace switch with another one.

BOILER SYSTEM DIAGNOSTICS - Flow Switch - Optional PROBLEM POSSIBLE CAUSE SOLUTION

Reed switch activates when

tested with external magnet

Magnet fouled and will not move If magnet does not move freely within its housing, remove debris to unstick it.

Reed switch misadjusted To adjust it for the flow the system is producing, loosen the reed switch and move it in its

Magnet is bad If reed switch activated the boiler when tested with a hand held magnet, the internal magnet may

Reed switch does not

activate when tested with

external magnet

Reed switch is bad If reed switch does not activated the boiler when tested with a hand held magnet, the reed

switch may need replacement.

Problem elsewhere in system See diagnostics listed above.

BOILER SYSTEM DIAGNOSTICS - Thermostat PROBLEM POSSIBLE CAUSE SOLUTION

Thermostat set improperly Thermostat set too low Set thermostat properly and ensure connections are not loose or corroded.

Boiler fires when thermostat

jumped, but will not fire with

thermostat in circuit

Thermostat bad Replace Thermostat.

Boiler will not fire when

thermostat jumped Problem elsewhere in system

Continue with boiler control diagnostics. If boiler still does not fire, the thermostat may need

replaced.

BOILER SYSTEM DIAGNOSTICS - High Temperature Limit PROBLEM POSSIBLE CAUSE SOLUTION

Electrical continuity through

switch

Connections loose or corroded Check connections to high temperature limit switch to ensure that they are not loose or

corroded.

Problem elsewhere in system If there is continuity through the switch but the boiler still does not fire, there is a problem

elsewhere in the system. Continue with boiler control diagnostics.

No continuity through switch Switch bad Replace switch.

BOILER SYSTEM DIAGNOSTICS - Low Fuel Shut-Off PROBLEM POSSIBLE CAUSE SOLUTION

Fuel level low Switch may be operating properly Add fuel and retest.

Fuel level proper Level sensor stuck Check level sensor for proper movement. Clear, repair, or replace sensor assembly.

Reed switch bad Check level sensor for proper action. Replace switch if needed.

Rev. 2/3/2016